Nio USA, Inc.

Nio Technology (Anhui) Co., Ltd.

Adam H Ing

Alexander Jeffrey Smith

Austin Lawrence Newman

Rick Rajaie

Peng S Chen

Miaosen Shen

Yadunandana Yellambalase

Feng Guo

Marc W Juzkow

Brittany M Repac

Shubham Saurav

Methods and systems are provided for managing multi-battery systems, such as those utilized in an electric vehicle. Multi-battery systems comprise batteries providing power in parallel, thereby making each battery available to the vehicle and avoiding the weight of transporting a backup battery. The methods and systems provided allow for a fault in one battery, in a parallel configuration with at least one other battery, to be detected and managed.

Split battery for autonomous driving

Embodiments are directed to managing battery pack exchanges for an electric vehicle by maintaining current swap station information for a number of battery pack swap stations, receiving navigation information from the vehicle indicating a travel route of the vehicle, and receiving current vehicle information from the vehicle and related to a battery pack installed in the vehicle. A battery pack swap plan can be determined based on the swap station information, the navigation information, and the vehicle information. The plan can indicate a selected replacement battery pack at each of one or more selected battery pack swap stations. Information defining the battery pack swap plan can be provided to the selected battery pack swap stations and the vehicle. The stations can reserve the selected replacement battery pack and the vehicle can update the travel route based on the battery pack swap plan.

Optimization of battery pack size using swapping

A battery connector, including a flexible circuit including a first set of electrical circuitry connecting to a plurality of energy storage cells, where the first set of electrical circuitry terminates at a first connection point at the battery connector; a controller including components to control the energy storage cells connected to a second set of electrical circuitry terminating at a second connection point at the battery connector; where the first connection point and the second connection point are electrically connected.

Serviceable flex circuit for battery module

Methods, systems, and devices of an electrical vehicle are provided that recognize a catastrophic power system fault with one or more drive power sources of the vehicle and in response driving to an identified safe ejection location, ejecting the faulty drive power sources, and driving to a safe parked location or outside a predetermined safe range. Upon reaching the safe ejection location, the driver or vehicle can evaluate the location using imaging sensors to determine whether the location is free of objects, animals, or people. If not, the vehicle may autonomously drive or be driven to another safe ejection location. After detecting and prior to ejecting the faulty drive power sources, the vehicle may send warning messages, including information about the power system fault, to at least one device or third party. After ejection, the vehicle may be driven to a safe parked location or outside a predetermined safe range.

Faulty power source ejection in a safe zone

Methods and systems are described that maintain and service electric vehicle battery packs and assemblies. The methods and systems automatically remove a used battery pack from an electric vehicle, replace the used battery pack with a charged battery pack, and service the removed used battery pack for subsequent vehicle installation. The servicing of the used battery pack includes removing a desiccant cartridge from the used battery pack and renewing a desiccant material associated with the desiccant cartridge. This desiccant material may be renewed by drying the desiccant cartridge using a heater. The used battery pack may be conveyed to a battery charger to charge the used battery pack to a predetermined charge level. The renewed, dry, desiccant cartridge may be attached to any battery pack and installed in an electric vehicle after the battery pack has been charged.

Method and system for preventing moisture accumulation in battery packs

A thermal management system of a battery of an electric vehicle proactively manages the temperature of the battery based on sensor data and sets limits to control cooling and heating of the battery. Using the data gathered from an autonomous drive platform, a highly-efficient control system which uses predictive modelling can be created. A control system predicts the battery final temperature and determines if cooling and/or heating is necessary for the route. If cooling and/or heating is not necessary, the thermal management system may be simply turned off to save energy. This is a dynamic approach which should optimize energy usage under all situations using trip predictive information (from GPS, route-calculation algorithms, and weather information), and thermal model predictive controls to determine battery final temperatures.

Systems and methods of battery thermal management

A laminated busbar assembly includes positive and negative leads supported by an insulative layer. The insulative layer as well as the positive and negative leads are thin and flexible, thus facilitating connection of the positive and negative leads with the terminals of the electric cells of a battery module. The laminated busbar assembly may include voltage measurement wires and/or temperature sensors for measuring voltage and/or temperature, respectively.

Laminate busbars for battery module design

Systems and methods of detecting leakage and other issues with electrical battery housings are provided. By using an air compressor to alter the air pressure within a battery housing, a processor may detect an abnormal rate of change in the air pressure within the battery housing as compared to a rate of change of an ideal battery housing.

Systems and methods for diagnosing seal integrity in a battery

An energy storage device having improved safety is provided, and methods of manufacturing the same. The device can be an electrochemical cell that includes: a positive electrode including a positive electrode active material in electrically conductive contact with a positive electrode current collector; a negative electrode including a negative electrode active material in electrically conductive contact with a negative electrode current collector and a negative electrode tab connected to the negative electrode current collector and a negative electrically conductive member; an electrically insulative and ion conductive medium in ionically conductive contact with the positive electrode and the negative electrode; and an outer case containing the positive electrode, negative electrode and electrically insulative and ion conductive medium, where the outer case comprises a scored area connected to a cooling plate.

Method and system for secondary internal current mechanisms for a lithium-ion cell

A multiple-zone thermocouple battery module temperature monitoring system is provided configured to determine a plurality of temperatures along a depth of the battery module at different locations. The system may include a number of temperature probes each including a first temperature sensor oriented at a base of a group of cells in the module and a second temperature sensor oriented at an upper portion of the group of cells in the module. Providing upper and lower battery cell temperature sensors in each probe of the system allows a battery management system to detect and record a temperature gradient of the battery cells in the module at a number of different locations. These recordings can determine a gradient and temperature difference between the upper and lower battery cell portions over an operable threshold difference, and command a thermal management system to return the battery module to limits within the operable threshold.

Multiple-zone thermocouple battery module temperature monitoring system

Embodiments include a junction box for an electric vehicle. The junction box includes a charging port to receive power from an external power source, and a plurality of switching elements to control electrical connections between the charging port, a first battery, and a second battery. On/off states of the plurality of switching elements control whether the charging port, the first battery and the second battery are connected in a first configuration or a second configuration.

Power systems and methods for electric vehicles

Methods and systems for creating a battery module. A battery cell can include a cooling device that cools a busbar and a power electronics package. To allow the cooling device to be attached to the busbar and allow the cooling device to cool both the power electronics and the busbar, the cooling device is mounted on the busbar with the busbar held between two portions of the cooling device and with the power electronics mounted on an opposite side of the cooling device from the busbar. The fluid or phase change material may then circulate through a cavity in the cooling device to cool both the power electronics and the busbar.

Power electronics with integrated busbar cooling

Systems of an electrical vehicle and the operations thereof are provided. In particular, a vehicle is described with the ability to gather State of Charge (SOC) information as well as State of Health (SOH) information for one or more batteries in a vehicle and then display both SOC and SOH information to a driver of the vehicle as well as other interested parties. The displayed SOH information may be accompanied by suggestions to modify driving and/or charging behaviors that will improve or contribute to a slower degradation in the SOH of the batteries.

Reporting of vehicle battery state of health and charge

A power module for a vehicle includes a bidirectional voltage converter to i) convert a first voltage to a second voltage and convert the second voltage back to the first voltage, and ii) convert the first voltage to a third voltage and convert the third voltage back to the first voltage. The power module includes one or more power sources coupled to the bidirectional voltage converter and to supply power to auxiliary components of the vehicle. The power module includes a controller to control the bidirectional voltage converter and the one or more power sources. The first voltage is for supplying power to a powertrain of the vehicle, and the second voltage and the third voltage are for supplying power to the one or more power sources.

Growing community of inventors

Santa Clara, CA, United States of America

Adam H Ing